Wire feeder



Feb. 16, 1960 HQG. RATH ETAL 2,925,170

WIRE FEEDER Filed May 9, 1956 a Sheets-Sheet 1 mvewrons- HOWARD G. RATH ALFRED J. MILLER JOHN A. KRATZ M/MMQ/ A T TORNEY Feb. 16, 1960 H. s. RATH EIAL WIRE FEEDER 3 Sheets-Sheet 2 Filed May 9. 1956 m w w w Feb.

Filed y 9, 1956 H. G. RAT AL ill!"- llllllllil HIIH l "m w llllllwl n g i nnlnulmr;

3 -Sheet 3 IN ns ALFRED J. MILLER JOHN A. KRATZ BY 54w/ f JAM97 232.53% Patented Feb. 16, 1%66 fig WIRE FEEDER Howard G. Rath, Fanwood, andAlfred J. Miller, West field, N.J., and John A. 'Kratz, Bronxville, N.Y., assignors to Union Carbide Corporation, a corporation of New York Application May 9, 1956, Serial N 0. 583,870 6 Claims. (Cl. 203-250) from a source [of supply to the feed roll and thence to the .arc zone; at a controlled rate consistent with the process requirements. However different apparatus has beenprovided for each of several different processes;

In submerged arcwelding in which the arc is shielded beneath a blanket of granular flux a characteristic apparatus was developed; In inert gas shielded metal are 30 welding known as sigma welding, different apparatus was provided for feedingsmaller than normal wire at higher 2 eners and torches. The assembly is adjustable to provide right and left hand feed or reverse feed, and the feed roll shaft is preferably double ended to provide simultaneous wire feed, or to drive accessory equipment.

In the drawings:

Fig. 1 is a side elevation of a wire feeder according to the preferred embodiment of the present invention;

Fig. 2 is a perspective view of the same;

Fig. 3 is a perspective view at another angle showing parts disassembled;

Fig. 4 is a transverse section through the gear reduction unit axially of the feed roll shaft;

Fig. 5 is a longitudinal section taken along the line 5-5 of Fig. 4;

Fig. 6 is an elevation of a modified gear reduction unit broken away to show the gear train;

Fig. 7 is a modified form of Fig. 4, showing the double ended feed roll shaft;

Fig. 8 is an end elevation roll cast plastic hub; and

Fig; 9 is a section taken along line 99 of Fig. 8.

The wire feeder shown in the drawings comprises a motor 1!) and a gear reduction box 12 secured together as a unit. The box 12 journals a feed shaft 14 transverse to the motor shaft, and the entire unit is mounted for adjustment of the feed shaft 14 about the motor axis to any selected angle of wire feed in a plane radial to partly in section of the feed the motor axis. For this purpose the unit is provided than normal speeds and carrying higher than normal 1 current densities. The greater flexibility of the smaller wire caused the problem of buckling or shaving of the wire, and the gas shielding caused the problem of delivering the wife centrally through the gas cup for uniform shielding.

Inmagnetic flux welding, a revolving magnet is employed to feed the flux at a constant rate and the wire feeder has the problem of driving the revolving magnet as well -as the wire. In semi-automatic tungsten arc welding filler wire is fed to thetungsten arc, and the previous Wire'feeders were not siiitable for]. this process.

3t keyed on the feed shaft 14.

' shaft 14.

The 'mainobject's of the present invention are to avoid the difiicillties referred to abOVeQand to provide a Wire feedersatisfactoryIfor and interchangeable in'thecvar fl io'us consumable wire processes? Accordinglto thepresent;invention,the wire feeder comprises a motor gear reduction unit of "symmetrical casing construction and having a transverse feed 'roll' shaft, means for adjusting said unitjabout themot or jaxis to a selected'angle, anqac'cessory support bracket, and means-for? adjusting the'a'ccesfsory support. bracket about the axis 'of said feed roll shaftjto a'selected angle of wire feed." Preferably theadjustment about the motor axis' is provided by a concentric mounting ring clamp and a mating circular surfaceon the motor gear reduction unit. Preferably the gear reduction unit has an insulating shoulder concentric with the feed roll shaft, and the accessory bracket has a circular clamp for adjustment about the feed rollshaft. The gear reduction unit pref-- shaft, and the feed roll preferably has a hollow interior in which is molded a plastic hub keyed to the worm. gear shaft. 'The accessory bracket has inlet and outlet '1 to the wire feed, or may be modified thigeestage formjof Thein shaft 28 journaled in the gear box 12. The shaft 28 has an enveloping worm 2) driving an enveloping worm gear The double enveloping worm and gear drive contribute to the precision control of speed of the wire feed as a function of wire burn off rate. A wire feed roll 32 is keyed on one end. of thefeed At the other end a removable vided' for access to, the shaft 14 and gearing. 7

gear train. is shown'in Fig. 6. or pinion 26 drivesa gearj34 on a sleeve with a 35; meshing with a gear36 on-lsleeve with a 7.; [The pinion37 mesheswith the gear 27 keyed orrnshaft 28.

pinioni ended feed roll shaftj Fig. The second en dQ S. extends beyond its journal in the gear 130x 12; and as shown may r eceivea gear to drive a' rotary mag riet for feeding magnetic in timed relation to'receive a second wireffeed rollfor driving a second wire. c

:The wire feed roll 32 is shown in detail in Figs. 8 and 9. The knurled metal rim 40 has a hollow interior 41 erably journals a' double enveloping worm gear and Worm' sockets aligned with the periphery of the feed roll for in-.

terchangeably feceiving equipment such aswire straighte an' arm 5221 pivoted on the bracket 46 and pressed toshown as a three-lobed boring, in which is cast a plastic hub 42 having a keyway 43 for fixing the roll 32 onto the feed shaft 14. This eliminates tedious machining otherwise required to prevent eccentricity of the rim 46, when fitting insulation between the rim and the drive Bolted to'the side of the gear box 12 is an insulating peripheral shoulder44 concentric with the'feed shaft 14 on which is mounted an accessory bracket 46. The bracketj46 has a circular clamp 43 adjustably. engaging th'shoulder44. A-wire back up roll 50 is journaled in plate $9 is proseas-n70 ward. the feed roll 32 by a spring 53 compressed by a screw 54. The arm 52 being precision pivoted on the bracket 46 determines a fixed point of tangency for the back up roll 50 against the feed roll 32.

The accessory bracket has a fixed inlet guide socket 56 and a fixed outlet guide, socket 58 aligned with the nip between the back up roll 50 and the feed roll 32. This. alignment isl preserved in all? positions. of adjustment of, the bracketv 46. about the peripheral shou1derk44 concentric withtthe feed. roll.shaft..

Fig. 1 shows, a. wire straightener mountedinthe inlet socket 56, and a torch 62 mounted in the outlet socket, 58;. These; are, interchangeable with. each. other and o her; accessony, fittings. The; wire; can be fed; in either directionby;interchanging; component; parts of acee ry t ngs;

To convert a right hand drive to a; left hand. drive, the plate, 39; is removed and the' shaft 14 and gearing reversed, to bringthe feedroll; 32 to the; oppositeside; Then the accessoryclarnp 46jsturned180f on theperipheral shoulder 44. Inasmuch as this brings the back up'roll 50to the other side 'of the feed roll 32,,the Wire guideg60 is taken out of the inletsocket-56 and mountedinoutlet; socket 58, from-which-thetorch 62 is removed and;inserted in socket 56.

What is claimed is; I

1. Wire feeder comprising a motor gear reductionunit includinga motor having a -mot r. shaft and a gear. box securedto said motor and, journaling a, feed rollv shaft transverse-to said motor shaft, a wire feed roll keyed on saidtr ansverse feedrollshaft, amounting ring havback up roll toward said wire feed roll, and means for worm driving said transverse feed roll shaft, saidfeed roll having a hollow interior with a plastic hub moulded therein and keyed on said shaft, means for adjusting said unit about the motor axis to a selected angle of said feed roll shaft, an accessory support bracket, a wire guide back up roll yieldably mounted on said accessory support bracket and journaled eccentric to said feed roll shaft, means mounted on said bracket for urging said adjusting said bracket about the axis of said plastic feed roll hub. I a

4. Wire feeder comprising a motor gear reduction unit including a. motor havinga motor shaft; and agea'rfboi secured to saidmotor. and journaling a feed roll -shaft transverse to said motor shaft, a'wire feedrollkeyedon said transverse feed roll shaft, a mounting ring" having a circular internal surface: concentric with; said. motor shaft, said motor gear reduction unit having a circular external surface concentric withsaidmotor shaft and mating with said internal surface and rotatable therein, an external peripheral shoulder of insulating material secured: to said unit. concentric with said. wire engaging feed roll, and. an accessory support bracket, azwireizguide backrup; roll 1 yieldably. mounted on said accessory: sup.- 5

port bracket and journaledaeccentric to said f'eediroll shaft, means mounted on said bracket for urging said back-up; 'roll; toward said wire" feed roll, said bracket ing a;circular internalsurface concentric withrsaid motor 5- 1 shaft, said motor, gear reduction unit having a circular,

external. surface concentric withv said motor, shaft and matingf with said internal surface and rotatable therein.v for adjustingsaidunit-aboutthemotor axisto a selected. angle of said feed roll shaftin a planevradial to. the motor axis, an, accessory support bracket, a wire guidev backup roll, yieldably mounted, on said accessory sup: port bracket and 'journaled eccentric to said feed roll shaft, means mounted ,on said bracket for urging said back-up roll, toward said wire feed roll, and, means for adjusting said accessory support bracket about the axis of said" feed roll shaft' toa selected angle of'wirenfeed in alpla'ne' radial to said feed roll shaft. 7 I 1 V V 2. Wire feedercomprising a motor gear reduction unit, including amotorfhaving a motor shaft and'a gear box securedito said'm'otor' and journaling a feed roll shaft having; a: circularclamp engaging. said insulating :peripl'ieeralj: shoulder for adjustmentto anyrselected1angle ofi wire feed abouttthemxiszof saidwire engaging feed rolli.

5;:Wire feeder comprising aamotorgear rcductioniunit;

including agmotorshaft and a-.- gear box secured toesaidr motor-:1 and journali'ng a feed roll: shaft a transverse; to; I

said )l'IlOIOI. shaft, a 1 wire. feed l rollkkeyedl on: said :transverse'feedj roll shafta mounting zring'zhavingiiaacircular internalisurface vconcentric withqsaid motorshaft; said? motort; gear reduction unit having; a: circular-"external;

surfacepconcentric, with, saidmotorrshaftwand mating withgsaid internal surface; and rotatable therein? for; adajusting said unitabout the motor axis to-aqselected-gangle;

of. saidfeed roll shaft in a'plane. radial to the motor. axis;

" tan-accessoryv support bracket, a wire guideaback-up roll yieldably, mounted on said accessory supporttbracket and: journaled eccentric to said feed roll shafg: meansemeunted on said bracket for urging said back-up roll'towardgsaid; wire feed roll, means foradjusting said'z accessory support bracket about the'axis of said wir'e feed 11311 1053;

transverse to said motor shaft, a wire feed'roll' keyed on said't-ransyerse feed roll shaft; a mounting ring havingiai' circular internal surface concentricwith said motor shaft,

surface for adjustment of said unit*thereinitoiselectively" hold said feed rollshaftin any desired angular wiref 'ed positionabout the motor axis with'respect to sa'idmount I ingfring an accessory supportbrackega wire guideback" up roll mounted on said iaccessory support, bracket ecce'ri tri c to} said feed roll;shaft,* meanson urging said back-up rolltowardsaidwire feed roll, and meansffor adjusting said'accessory'support bracket about .the ax i s of'said feedroll sh'aftto a: selected angle of wire: feedin aplane radiahtosaidfeedI'rollshaft;'

3. Wirefeeder comprisinga motor gear reductionrunit including a motor having a' motor shaftand a gearbox secured to said motor and journalinga feed roll" transverse to saidfeedrollshaft, a wire feed rollkeyedi onrsaid transverse feed, roll shaft, a mounting ,hav ing a circular-t internaltsurface,concentriewithsaid'motor, shaft, said motor gear reduction unit having-, a c-ircular,

I external surface concentric withs said motor shaffland:

mating with said inte,rna1; surface and rotatable, therein; said gear. boxeiournaling at double, enyelcpinggeart and,

selected angle of-wire feed in a'plane vradialgtmsaidgfeedi roll and inlet and outlet.socketsfixedion said accessory support bracket inalignment with -and'tangent to said wire;;feed roll in all po'sitionsf of "adjustment;

emotor axiszto asselected,

' up; roll-yieldably gmountedgon, said: accessory support;

bracket and' journaled. eccentric to said feedroll shaft,

means mountedon said bracket for urgingsaiduback-up I roll toward-said wire feed roll, means for-adjusting said accessory} support bracket about the; axis of said feed roll; shaftto a selected angl e of wire; feedvi l-t ii ne radial, to rsaid feed; roll shaft,- the other end of saidQfeedi r011 shaft projecting, clear; out of the other side 0f said a Wi eeder mpo i a o sear r s o f n fl ineluding aa motor havi g a, a motor shaft and 'a'gear box "secured to; said motor and "ournalinga feed-eroll =shaft:- transverse to saidmotoi'; shaft, a wire-feed. roll ,keyedv t on said transverse feed roll shaft' a mounting ,ring, having culan n e lr e n e tt w th sai pmoto shaft, said motor gear reduction unit having I external surface: I concentric vv it-h; said motor: I haft and; mating withgsaidinternal surface. and rotatable; thereinc "fqr adjus g;. id it b ut. I I angle of said feed roll-shaftin a plane'radialito the motorg' ircfulac ean-boxland forming a driving head -for, feedinggother References Cited in the file of this patent 2,453,817 UNITED STATES PATENTS 3 2 3 222? Stange Aug. 7, 1,700,736 Brennan Feb. 5, 1929 5 1,733,812 MacRae Oct. 29, 1929 2,066,163 Stephens Dec. 29, 1936 2,079,956 Burgett May 11, 1937 2,182,575 Baird et a1. Dec. 5, 1939 ShaIkhauser Nov. 16, 1948 Jacobson Feb. 28, 1950 M-ackman et a1. Dec. 2, 1952 Clary et a1 'Ju11e 18, 1957 OTHER REFERENCES Machine Design, Designing Fabricated Nylon Parts, March 1954, pp. 153-159, copy in Sci. Lib. and Div. 12. 

